Multi-chamber submerged combustion melter and system

ABSTRACT

A submerged combustion melter and system are disclosed. The submerged combustion melter includes a bottom wall, at least one side wall extending upwardly from the bottom wall, a crown extending inwardly with respect to the at least one side wall and over the bottom wall to establish a melting chamber, an exhaust port configured to exhaust gas from the melting chamber, at least one baffle extending from the at least one side wall to divide the melting chamber into melting sub-chambers that share the exhaust port, at least one inlet configured for introducing a glass batch into the submerged combustion melter, and at least one outlet configured to remove molten glass from the at least one melting chamber.

This patent application discloses devices for glass manufacturing, andmore particularly, devices for melting a glass supply in a furnace ormelter.

BACKGROUND

Submerged combustion melting (“SCM”) is based on enhancing heat transferby mixing combustible fuels and oxidants with raw glass material andfiring the fuels and oxidants under the surface of and directly into theglass material to be melted. The contact between the raw glass materialand the combusting fuels and oxidants generates a bubbling bath ofmolten glass with high rates of mass and heat transfer.

SCM furnaces or melters can have an inlet in a furnace wall, usuallynear a roof or top surface, for delivering a glass batch into thefurnace to be melted into molten glass and can have an outlet forremoving molten glass. SCM furnaces can operate at high meltingtemperatures of 1000° C. to 2000° C. or more.

BRIEF SUMMARY OF THE DISCLOSURE

The present disclosure embodies a number of aspects that can beimplemented separately from or in combination with each other.

A submerged combustion melter in accordance with one aspect of thedisclosure includes a bottom wall, at least one side wall extendingupwardly from the bottom wall, a crown extending inwardly with respectto the at least one side wall and over the bottom wall to establish amelting chamber, an exhaust port configured to exhaust gas from themelting chamber, at least one baffle extending inwardly from the atleast one side wall to divide the melting chamber into at least twomelting sub-chambers that share the exhaust port, at least one inletconfigured for introducing a glass batch to the submerged combustionmelter, at least one outlet configured to remove molten glass from theat least one melting chamber, and an exhaust port configured to exhaustgas from the melting sub-chambers, where the melting sub-chambers areconfigured to direct product flow in an undulating flow path between theat least one inlet and the at least one outlet.

A submerged combustion melter system in accordance with one aspect ofthe disclosure includes a submerged combustion melter and at least oneburner proximate to the submerged combustion melter. The submergedcombustion melter and system disclosed herein provide a melter with aseries of melting sub-chambers that direct molten glass flow in anundulating flow path and provide one exhausting system for the series ofmelting sub-chambers.

BRIEF DESCRIPTION OF THE DRAWINGS

The disclosure, together with additional objects, features, advantagesand aspects thereof, will be best understood from the followingdescription, the appended claims and the accompanying drawings, inwhich:

FIG. 1A is a schematic cross-sectional view illustrating a submergedcombustion melter having at least one baffle that creates a series ofmelting sub-chambers with a single exhaust system, a verticallyundulating flow path, and an outlet below melt-level, in accordance withan illustrative embodiment of the present disclosure.

FIG. 1B is a fragmentary cross-sectional view illustrating the baffle inFIG. 1A, where the baffle is shown within a portion of the submergedcombustion melter, in accordance with an illustrative embodiment of thepresent disclosure.

FIG. 1C is an elevational view showing an end cap of the baffleillustrated in FIG. 1B, in accordance with an illustrative embodiment ofthe present disclosure.

FIG. 1D is an elevational view showing the baffle illustrated in FIG.1B, in accordance with an illustrative embodiment of the presentdisclosure.

FIG. 1E is an elevational view showing the baffle illustrated in FIG.1B, in accordance with an illustrative embodiment of the presentdisclosure.

FIG. 1F is an isometric view showing the baffle illustrated in FIG. 1B,in accordance with an illustrative embodiment of the present disclosure.

FIG. 2 is a schematic cross-sectional view illustrating a submergedcombustion melter having at least one baffle that creates a series ofmelting sub-chambers with a single exhaust system, a verticallyundulating flow path, and a melt-level outlet, in accordance with anillustrative embodiment of the present disclosure.

FIG. 3 is a schematic cross-sectional view illustrating a submergedcombustion melter having at least one baffle that creates a series ofmelting sub-chambers with a single exhaust system, a horizontallyundulating flow path, and a melt-level outlet and/or an outlet belowmelt-level, in accordance with an illustrative embodiment of the presentdisclosure.

FIG. 4 is a schematic top plan view illustrating the submergedcombustion melter of FIG. 3.

FIG. 5A is a schematic top plan view illustrating a submerged combustionmelter having at least one baffle that creates a series of meltingsub-chambers with a single exhaust system, a vertically undulating flowpath, and an outlet below melt-level, in accordance with an illustrativeembodiment of the present disclosure.

FIG. 5B is a schematic cross-sectional view illustrating the submergedcombustion melter of FIG. 5A and taken along line 5B of FIG. 5A.

FIG. 6A is a schematic top plan view illustrating a submerged combustionmelter having at least one baffle that creates a series of meltingsub-chambers with a single exhaust system, a horizontally undulatingflow path, and an outlet below melt-level, in accordance with anillustrative embodiment of the present disclosure.

FIG. 6B is a schematic cross-sectional view illustrating the submergedcombustion melter of FIG. 6A and taken along line 6B of FIG. 6A.

DETAILED DESCRIPTION

A general object of the present disclosure, in accordance with at leastone aspect of the disclosure, is to provide a submerged combustionmelter that includes at least one baffle or skimmer for changing moltenglass batch flow paths and for better control of the batch flow insidethe melter. The baffle(s)/skimmer(s) can increase the batch minimumresidence time by guiding the batch material flow. Additionally, thebaffle(s)/skimmer(s) direct the flow of the raw batch materials andmolten glass within the melter to attain the residence time needed formelting of the raw materials, which reduces or eliminates theshort-circuiting of the un-melted raw batch materials from the inlet tothe outlet, so that undissolved silica or other raw batch materials willnot exit the melter along with the molten glass.

An efficient method for melting glass can include using submergedcombustion melting (“SCM”). SCM is based on enhancing heat transfer bymixing combustible fuels and oxidants with raw glass material and firingthe fuels and oxidants directly into and under the surface of the glassmaterial to be melted. The contact between the raw glass material andthe combusting fuels and oxidants generates a bubbling bath of moltenglass along with high rates of mass and heat transfer.

The melting apparatus and method described herein may be used indifferent types of glass melting including SCM. In SCM, an air-fuel oroxygen-fuel mixture is injected directly into a pool of raw materialswithin a melting chamber or melter. Burners can be arranged at thebottom and sides of the chamber beneath the top surface of the materialand can stimulate rapid melting of the raw materials by combusting thefuel within the pool of raw materials. Combustion gases bubble throughthe raw materials and create turbulent mixing of the raw materials at ahigh-heat transfer rate, melt the raw materials into the molten glass,and mix the molten glass to create a homogeneous glass. Once the moltenglass achieves a uniform composition, it can then be removed or drainedfrom the chamber to be further processed and/or used to form desiredproducts.

Utilizing SCM yields intense combustion and direct-contact heat transferas the combustion gases bubble through the raw materials and the moltenglass and results in a high rate of heat transfer further resulting inhigh thermal efficiency. Due to these advantages, SCM uses less energyto melt the raw materials and can utilize a smaller melter and/orfurnace compared to other melting methods. Additionally, the moltenglass spends less time in the melter and is rapidly mixed.

SCM systems can be simple and inexpensive because the SCM chamber istolerant of a wide range of raw material and cullet size, can acceptmultiple types of raw glass batch material feeds, and does not requiremixing of the feed material prior to addition to the chamber. However, aglass batch that is fed to the melter may exit in a relatively shorttime for some submerged combustion melters used in the glass industry,which may risk an unmolten or partially unmolten batch and limitimprovement of throughput.

Consequently, the present disclosure is directed to a submergedcombustion melter and system that employs at least one baffle (orskimmer) to form a series of melting sub-chambers configured to guideand control the flow of raw batch materials and molten glass within thesubmerged combustion melter. Additionally, the series of meltingsub-chambers in the disclosed submerged combustion melter share oneexhaust system.

FIGS. 1-6B illustrate a submerged combustion melter system 100 and asubmerged combustion melter 102 in accordance with an illustrativeembodiment of the present disclosure. The submerged combustion meltersystem 100 and the submerged combustion melter 102 can include at leastone bottom wall 104, at least one side wall 106, and a crown 108 toestablish a melting chamber 112. Additionally, the submerged combustionmelter system 100 and the submerged combustion melter 102 can include atleast one baffle 110 configured to subdivide the melting chamber 112 andat least partially define two or more melting sub-chambers 112 a, 112 b,112 c, 112 d, 112 e, 112 f, 112 g disposed within the overall meltingchamber 112 in the submerged combustion melter system 100 and thesubmerged combustion melter 102. It will be appreciated that thesubmerged combustion melter 102 can include a variety of configurations,for example, more or less baffles and/or more or less meltingsub-chambers than shown in FIGS. 1-6B.

As illustrated in FIGS. 1-6B, a submerged combustion melter 102 caninclude a bottom wall 104. The bottom wall 104 can include a panel thatmay be cooled (e.g., fluid-cooled) using a variety of materials, such aswater, steam, or other appropriate fluids that can serve as a heatcarrier, or may be non-fluid-cooled. The bottom wall 104 can includematerials that can withstand thermal, chemical, and physical erosion andcorrosion. Additionally, the bottom wall 104 can include at least oneopening configured to receive a submerged combustion burner 124. As thesubmerged combustion melter 102 size is increased, the number of burners124 and openings in the bottom wall 104 can be increased.

In implementations, at least one side wall 106 can be disposed on andcoupled to the bottom wall 104. Similar to the bottom wall 104, eachside wall 106 can include material that can withstand thermal, chemical,and physical erosion and corrosion, and each side wall 106 may befluid-cooled, for example using water, steam, or other appropriatefluids configured to serve as a heat carrier, or may benon-fluid-cooled. In implementations, each side wall 106 can generallyextend perpendicularly from the bottom wall 104. In one specificembodiment, a submerged combustion melter 102 can include four sidewalls 106 that are coupled to the bottom wall 104 and at least partiallydefine a chamber within the submerged combustion melter 102. It iscontemplated that the submerged combustion melter 102 can include avariety of other configurations of side walls 106 (e.g., three sidewalls 106 or more) disposed on the bottom wall 104.

As depicted in FIGS. 1-6B, a crown 108 can be disposed on and coupled tothe side walls 106, where the crown 108, the side walls 106, and thebottom wall 104 define the submerged combustion melter 102. In aspecific embodiment, the crown 108, the side walls 106, and the bottomwall 104 can be coupled and configured in the form of a box, where theside walls 106 can be coupled perpendicular to both the bottom wall 104and the crown 108. In other embodiments, the submerged combustion melter102 may include multiple side walls 106 located between and connectingthe crown 108 and the bottom wall 104. In an example of this embodiment,a first side wall 106 a can be coupled to the crown 108 perpendicularly,and a second side wall 106 b can be coupled to both the first side wall106 a and the bottom wall 104 at an angle (e.g., 45° each connection),where the crown 108 and the bottom wall 104 can be parallel. It iscontemplated that the side walls 106 of the submerged combustion melter102 may include a variety of other configurations.

The crown 108 can be formed of materials that are capable ofwithstanding thermal, chemical, and physical erosion and corrosion. Inimplementations, the crown 108 may be fluid-cooled utilizing water,steam, or other suitable heat transfer fluids, or may benon-fluid-cooled. Additionally, an exhaust port 118 can be disposed onand/or extend through the crown 108 for exhausting combustion gases fromthe submerged combustion melter 102 and each melting sub-chamber 112 a,112 b, 112 c, 112 d, 112 e, 112 f, 112 g. The exhaust port 118 can serveas a single exhaust for each respective melting sub-chamber 112 a, 112b, 112 c, 112 d, 112 e, 112 f, 112 g disclosed herein and avoids therequirement of multiple exhausting duct systems.

In implementations, the distance from a first side wall (e.g., a sidewall proximate to an inlet) to a second side wall (e.g., a side wallproximate to an outlet and opposite from the first side wall) can definea longitudinal axis. The distance from a third side wall to a fourthside wall (e.g., where the third side wall and the fourth side wall areopposite from each other and each abut the first side wall and thesecond side wall) can define a laterally transverse axis, where thelaterally transverse axis is perpendicular to the longitudinal axis. Thedistance from the bottom wall to the crown can define a verticallytransverse axis.

In embodiments, at least one inlet 114 can be disposed on and extendthrough the crown 108 and/or a side wall 106. In the embodiments shownin FIGS. 1-6B, the inlet 114 extends through the crown 108. The inlet(s)114 can be configured to introduce material to be melted (e.g., a glassbatch) into the submerged combustion melter 102 from, for example, abatch charger 128. In glass manufacturing, a glass batch can include rawor starting materials used to form a uniform homogenous composition. Theraw materials can include a variety of different chemical compositions(e.g., various oxides to form soda-lime-silica glass) and may be mixedwith cullet or recycled glass to constitute glassmaking materials. Theglass batch can be delivered or passed into a glass furnace or melter byway of a glass or batch charger 128. The batch charger 128 can becoupled to the submerged combustion melter 102 at any desired location(e.g., the crown 108, a side wall 106) and can have a feeding port(e.g., inlet 114) to pass glass batch into the submerged combustionmelter 102 to be melted. In a specific embodiment, a batch charger 128can be configured to deliver a glass batch through an inlet 114 thatextends through the crown 108 and into the submerged combustion melter102.

At least one baffle 110 (or skimmer) can be disposed in the submergedcombustion melter 102. Each baffle 110 may be fluid-cooled using steam,water, or other fluids suitable for heat transfer, or may benon-fluid-cooled, and can be formed of materials that are capable ofwithstanding thermal, chemical, and physical erosion and corrosion. Someexample materials suitable may include noble metals, for exampleplatinum and/or rhodium. It will be appreciated that the baffle(s) 110may comprise other suitable metals.

FIG. 1B illustrates an embodiment showing a cross-section of the baffle110 disposed within the submerged combustion melter 102. In thisembodiment, the baffle 110 extends between and/or through two side walls106 and proximate to the crown 108; however, it will be appreciated thatthe baffle 110 may configured in a variety of ways (e.g., coupled toand/or abutting the bottom wall 104, disposed equidistant from thebottom wall 104 and the crown 108, and the like). The baffle 110 isshown having an end cap 111, further illustrated in FIG. 1C, which isdisposed on the outside of one side wall 106 and the submergedcombustion melter 102. The end cap 111 can be configured to fasten thebaffle 110 to the side wall 106. Additionally, the end cap 111 can beconfigured to provide a heat transfer fluid reservoir, and may include afluid passage 113 and/or a tube 115 that can include a fluid inlet 117 aand/or outlet 117 b or to carry the heat transfer fluid. Whenfluid-cooled, the at least one baffle 110 may be configured to receivecooling fluid from at least one fluid-cooled side wall 106 and/or fromthe end cap 111. As shown in FIG. 1C, the end cap 111 may include aplate 119 (e.g., end wall of the baffle 110) and/or the tube 115configured for carrying the heat transfer fluid. Additionally, thebaffle 110 may include an end cap 111 for a non-fluid-cooled baffle 110or for a fluid-cooled baffle 110. In the embodiment shown in FIG. 1D,the baffle 110 is non-fluid-cooled and includes a refractory material121 (e.g., silicon dioxide (SiO2), aluminum oxide (Al₂O₃), and thelike). In the embodiments shown in FIGS. 1E and 1F, the baffle 11 isfluid-cooled. In this embodiment, heat transfer fluid can be containedand/or enter the end cap 111 through a fluid passage 113 and travelalong a path (e.g., a serpentine path) created by at least one wall 123disposed in the baffle 110. The heat transfer fluid may then return toand remain within the end cap 111 and/or may exit the end cap 111through a fluid passage 113. It will be appreciated that thefluid-cooled and/or the non-fluid-cooled baffle(s) 110 may include otherconfigurations and arrangements.

In implementations, a series of baffles 110 can be coupled to respectiveside walls 106 and configured so that molten glass (e.g., product flow)flows through the submerged combustion melter 102 and around each baffle110 in an undulated flow path 122. Each baffle 110 may or may not bedisconnected from the crown 108. In some instances, the baffle(s) 110can be permanently coupled to the side wall(s) 106. In some instances,the baffle 110 can be mechanically/manually movable, adjustable, and/orrepositionable. For example, the angle of the baffle 110 may beadjustable relative to the flow of the molten glass, the side wall 106,and/or the bottom wall 104. It will be appreciated that each baffle 110may be movable and/or repositionable using other means, such as with anactuator. In embodiments, the submerged combustion melter 102 caninclude a set of baffles 110 that are staggered from each other. Thebaffles 110 may be staggered from side-to-side and/or from top tobottom, where the crown 108 can be disposed at the top, and the bottomwall 104 can be disposed at the bottom.

In the exemplary embodiment illustrated in FIG. 1A, the submergedcombustion melter 102 can include a series of baffles 110 where thefirst baffle 110 is coupled to at least one side wall 106 proximate tothe inlet 114 and directs molten glass to flow between the first baffle110 and the bottom wall 104. A second baffle 110 can be coupled to aside wall 106 and may be coupled to and/or abut the bottom wall 104. Thesecond baffle 410 can be configured to prohibit flow of the molten glassbetween the second baffle 110 and the bottom wall 104, but insteaddirect molten glass to flow over the second baffle 110 (e.g., betweenthe second baffle 110 and the space proximate to the crown 108). In eachcase where a baffle is configured to prohibit flow of the molten glassbetween the baffle and the bottom wall 104, the baffle may or may not becoupled to the bottom wall 104. Additional baffles 110 (e.g., a thirdbaffle, a fourth baffle, a fifth baffle, and so on) can be similarlystaggered such that molten glass flows in a vertically undulated pattern(e.g., from top to bottom to top and so forth along the verticallytransverse axis) between the inlet 114 and the outlet 116 and flowsgenerally along the longitudinal axis as shown by the exemplaryundulated flow path 122 indicated in FIGS. 1 and 2. For instance, athird baffle 110 can be coupled to a side wall 106 and can direct moltenglass to flow between the third baffle 110 and the bottom wall 104,where the second baffle 110 is disposed between the first baffle 110 andthe third baffle 110. In the example shown in FIG. 1A, the outlet 116 isdisposed below the molten glass surface 120, and in the example shown inFIG. 2, the outlet 116 is disposed at the molten glass surface 120,although it is contemplated that the outlet 116 may be disposed in otherlocations in the submerged combustion melter 102.

The submerged combustion melter 102 can include a melting chamber 112,which can be divided into melting sub-chambers 112 a, 112 b, 112 c, 112d, 112 e, 112 f, 112 g. Each melting sub-chamber 112 a, 112 b, 112 c,112 d, 112 e, 112 f, 112 g can be defined by the bottom wall 104, atleast one side wall 106, and at least one baffle 110, where one side ofthe melting sub-chambers 112 a, 112 b, 112 c, 112 d, 112 e, 112 f, 112 g(e.g., proximate to the crown 108) can be open to a single exhaustchamber 134 and exhaust port 118, which can be configured to exhaustcombustion gases (e.g., flue gas 126). Each respective meltingsub-chamber 112 a, 112 b, 112 c, 112 d, 112 e, 112 f, 112 g in thesubmerged combustion melter 102 can be open and in fluid communicationwith the same exhaust chamber 134 and exhaust port 118. In a specificexample, a first melting sub-chamber 112 a can be defined by a firstbaffle 110, three side walls 106, and the bottom wall 104. In this sameexample, a second melting sub-chamber 112 b can be defined by the firstbaffle 110, the second baffle 110, two side walls 106, and the bottomwall 104. Additional melting sub-chambers can be likewise defined. Inthis way, the molten glass can flow through the series of meltingsub-chambers along an undulating flow path 122 to the outlet 116 whilethe flue gas 126 from each melting sub-chamber 112 a, 112 b, 1 l 2 c,112 d, 112 e, 112 f, 112 g exits the submerged combustion melter 102through a single exhaust chamber 134 and exhaust port 118. Inimplementations, the melting sub-chambers 112 a, 112 b, 112 c, 112 d,112 e, 112 f, 112 g may operate with different temperatures in eachmelting sub-chamber. The different temperatures may be controlled byusing different burners or different numbers of burners for each meltingsub-chamber. In one example, the same type and number of burners can beused, but with the burners operating at different gas and oxidant flowrates. Some example melting sub-chamber temperatures may include1100-1200 degrees Celsius (C.), 1200-1300 degrees Celsius (C.),1300-1400 degrees Celsius (C.), and 1400-1500 degrees Celsius (C.).

As illustrated in FIGS. 1 through 6B, the submerged combustion melter102 can include at least one outlet 116 configured for removing and/ordraining molten glass from the submerged combustion melter 102, forexample, to a finer. In implementations, the outlet 116(s) can extendthrough the bottom wall 104 and/or a side wall 106. For example, theoutlet 116 can be disposed on and extend through a portion of a sidewall 106 that is below a molten glass level 120. In another example, theoutlet 116 can be disposed on and extend through a portion of a sidewall 106 that is at the same level as or proximate to a molten glasslevel 120 (e.g., “melt level”). In some embodiments, the submergedcombustion melter 102 can include more than one outlet 116. For example,the submerged combustion melter 102 can include an outlet (e.g., a firstoutlet 130) that is at the same level as a molten glass level 120 and anoutlet (e.g., a second outlet 116) that is below the molten glass level120. In implementations, the outlet 116 can be disposed on a side of thesubmerged combustion melter 102 that is distal from a side of thesubmerged combustion melter 102 having the inlet 114.

As illustrated in FIGS. 1 through 4, a submerged combustion meltersystem 100 can include a submerged combustion melter 102 and at leastone burner 124 coupled to and/or proximate to the submerged combustionmelter 102. A burner 124 can be configured to fire natural gas or otherfuel and oxidant (e.g., air, oxygen-enriched air, oxygen) into a bath ofmaterial (e.g., glass batch) undergoing melting within the submergedcombustion melter 102. In implementations, a burner 124 can be disposedproximate to the bottom wall 104 and/or at least one side wall 106. Forexample, a submerged combustion melter system 100 can include a seriesof burners 124 proximate to the bottom wall 104 and corresponding with aseries of melting sub-chambers 112 a, 112 b, 112 c, 112 d within thesubmerged combustion melter 102. It is contemplated that the submergedcombustion melter system 100 can include a number of burners 124 (e.g.,one burner, two burners, and so forth) in a variety of configurations.The burner(s) 124 can be configured to heat the submerged combustionmelter 102 to temperatures suitably high to melt the glass batch (e.g.,1200 to 1600 degrees Celsius (C.)).

FIG. 2 shows an illustrative embodiment of a submerged combustion meltersystem 200 and submerged combustion melter 202 including a series ofbaffles 210. This embodiment is similar in many respects to theembodiment of FIG. 1A and like numerals among the embodiments generallydesignate like or corresponding elements throughout the several views ofthe drawing figures. Accordingly, the descriptions of the embodimentsare incorporated into one another, and description of subject mattercommon to the embodiments generally may not be repeated here.

In the exemplary embodiments illustrated in FIG. 2, the submergedcombustion melter 202 can include a series of baffles 210 coupled to atleast one side wall 106 and may extend partially above a melt level ofthe molten glass, where each baffle can be respectively staggered. Inimplementations, a melt level that is continuously varying can bemeasured and a moving average can be determined. In otherimplementations, the melt level can be determined by placing thesubmerged combustion melter 202 on load cells, and the weight of theglass can be measured and converted to a melt level. In an example, afirst baffle 210 disposed proximate to the inlet 114 can be coupled to afirst side wall 106 and a second side wall 106 opposite the first sidewall 106 (see 410 FIGS. 5A and 5B), where the first baffle 210 directsmolten glass to flow only between the first baffle 210 and the bottomwall 104. A second baffle 210 can be disposed between the first baffle210 and the outlet 116 and coupled to the first side wall 106, thesecond side wall 106, and the bottom wall 104, where the second baffle210 directs molten glass to flow over the top of the second baffle 210(e.g., between the second baffle 210 and the crown 108). Additionalbaffles 210 (e.g., a third baffle, a fourth baffle, a fifth baffle, andso on) can be similarly staggered such that molten glass flows in avertically undulated pattern (e.g., from bottom to top and so forthalong the vertically transverse axis) between the inlet 114 and theoutlet 116 and flows generally along the longitudinal axis as shown bythe undulated flow path 122 indicated in FIG. 2. The second baffle 210can be disposed between the first baffle 210 and a third baffle 210,where the third baffle 210 directs molten glass to flow only between thethird baffle 210 and the bottom wall 104. It is contemplated that themolten glass can flow in a combination of patterns and/or flow paths.For example, multiple baffles 210 can be positioned so that the moltenglass can flow simultaneously along a vertically transverse axis andgenerally along a longitudinal axis from the inlet 114 to the outlet116. In the example illustrated in FIG. 2, the submerged combustionmelter 202 can include an outlet 116 disposed at the molten glasssurface 120 (“melt level”).

FIGS. 3 and 4 show another illustrative embodiment of a submergedcombustion melter system 300 and a submerged combustion melter 302including a series of baffles 310. This embodiment is similar in manyrespects to the embodiments of FIGS. 1 and 2 and like numerals among theembodiments generally designate like or corresponding elementsthroughout the several views of the drawing figures. Accordingly, thedescriptions of the embodiments are incorporated into one another, anddescription of subject matter common to the embodiments generally maynot be repeated here.

In the exemplary embodiments illustrated in FIGS. 3 and 4, the submergedcombustion melter system 300 and the submerged combustion melter 302 caninclude a series of baffles 310 coupled to a side wall 106 and mayextend partially above a molten glass surface 120 of the molten glass,where each baffle 310 can be respectively staggered. For example, afirst baffle 310 disposed proximate to the inlet 114 can be coupled to afirst side wall 106, where the first baffle 310 directs molten glass toflow only between the first baffle 310 and a second side wall 106 thatis opposite the first side wall 106. A second baffle 310 can be disposedbetween the first baffle 310 and the outlet 116 and coupled to thesecond side wall 106, where the second baffle 310 directs molten glassto flow only between the second baffle 310 and the first side wall 106.Additional baffles 310 (e.g., a third baffle, a fourth baffle, a fifthbaffle, and so on) can be similarly staggered such that molten glassflows in a laterally undulated pattern (e.g., from side to side and soforth along the laterally transverse axis, horizontally undulated) andflows between the inlet 114 and the outlet 116 generally along thelongitudinal axis as shown by the undulated flow path 122 indicated inFIGS. 3 and 4. The second baffle 310 can be disposed between the firstbaffle 310 and a third baffle 310, where the third baffle 310 directsmolten glass to flow only between the third baffle 310 and the secondside wall 106. It is contemplated that the molten glass can flow in acombination of patterns and/or flow paths. For example, multiple baffles310 can be positioned so that the molten glass can flow simultaneouslyalong a laterally transverse axis and a vertically transverse axis andgenerally along a longitudinal axis from the inlet 114 to the outlet116. In the example illustrated in FIG. 3, the submerged combustionmelter 302 can include multiple outlets 116 (e.g., an outlet 130 at themolten glass surface 120 and an outlet 116 below the molten glasssurface 120).

FIGS. 5A and 5B show another illustrative embodiment of a submergedcombustion melter 402 including a series of baffles 410. This embodimentis similar in many respects to the embodiments of FIGS. 1 through 4 andlike numerals among the embodiments generally designate like orcorresponding elements throughout the several views of the drawingfigures. Accordingly, the descriptions of the embodiments areincorporated into one another, and description of subject matter commonto the embodiments generally may not be repeated here.

In the embodiment illustrated in FIGS. 5A and 5B, the submergedcombustion melter 402 includes a series of baffles 410 that are disposedalong a longitudinal axis and staggered along a vertically transverseaxis. The series of baffles 410 can direct the flow of molten glassalong an undulated flow path 122, where the molten glass flows betweenthe top (e.g., crown 108) and the bottom (e.g., bottom wall 104) of thesubmerged combustion melter 402 along a vertically transverse axis andgenerally flows along a longitudinal axis from the inlet 114 to theoutlet 116. For example, the molten glass can flow from a first meltingchamber 112 a between a first baffle 410 and the bottom wall 104 to asecond melting chamber 112 b. From the second melting chamber 112 b, themolten glass can flow over a second baffle 410 (e.g., between the secondbaffle 410 and the crown 108) into a third melting chamber 112 c and soforth until the molten glass reaches outlet 116. The series of baffles410 can define a series of melting sub-chambers 112 a, 112 b, 112 c thatshare the exhaust port 118. In this embodiment, the exhaust port 118 canbe disposed proximate to the center (e.g., about equidistant from theinlet 114 and from the outlet 116) of the crown 108.

FIGS. 6A and 6B show another illustrative embodiment of a submergedcombustion melter 502 including a series of baffles 510. This embodimentis similar in many respects to the embodiments of FIGS. 1 through 5B andlike numerals among the embodiments generally designate like orcorresponding elements throughout the several views of the drawingfigures. Accordingly, the descriptions of the embodiments areincorporated into one another, and description of subject matter commonto the embodiments generally may not be repeated here.

In the embodiment illustrated in FIGS. 6A and 6B, the submergedcombustion melter 502 includes the series of baffles 510 disposed alonga longitudinal axis and staggered along a vertically transverse axis.The series of baffles 510 can direct the flow of molten glass along anundulated flow path 122, where the molten glass flows between the sidesof the submerged combustion melter 502 along a laterally transverse axisand generally flows along a longitudinal axis from the inlet 114 to theoutlet 116. For example, the molten glass can flow from a first meltingchamber 112 a between a first baffle 510 and a first side wall 106 to asecond melting chamber 112 b. From the second melting chamber 112 b, themolten glass can flow between a second baffle 410 and a second side wall106 into a third melting chamber 112 c and so forth until the moltenglass reaches outlet 116. The series of baffles 510 define a series ofmelting sub-chambers 112 a, 112 b, 112 c, 112 d that are divided frommelting chamber 112, where the melting sub-chambers 112 a, 112 b, 112 c,112 d share the exhaust port 118. In this embodiment, the exhaust port118 is disposed proximate to the center (e.g., about equidistant fromthe inlet 114 and from the outlet 116) of the crown 108.

There thus has been disclosed a submerged combustion melter systems andsubmerged combustion melters for guiding and controlling molten glassflow while providing a single exhausting system that fully satisfies oneor more of the objects and aims previously set forth. The disclosure hasbeen presented in conjunction with several illustrative embodiments, andadditional modifications and variations have been discussed. Othermodifications and variations readily will suggest themselves to personsof ordinary skill in the art in view of the foregoing discussion. Forexample, the subject matter of each of the embodiments is herebyincorporated by reference into each of the other embodiments, forexpedience. The disclosure is intended to embrace all such modificationsand variations as fall within the spirit and broad scope of the appendedclaims.

The invention claimed is:
 1. A submerged combustion melter, comprising:a bottom wall; a plurality of side walls including a first side wall, asecond side wall, a third side wall, and a fourth side wall extendingupwardly from the bottom wall; a longitudinal axis extending from thefirst side wall to the second side wall; a laterally transverse axisextending from the third side wall to the fourth side wall, thelaterally transverse axis perpendicular to the longitudinal axis; acrown extending inwardly with respect to the plurality of side walls andover the bottom wall to establish a melting chamber; an exhaust portconfigured to exhaust gas from the melting chamber; a plurality ofbaffles including a first baffle and a second baffle, the first bafflecoupled to at least one side wall of the plurality of side walls and thesecond baffle coupled to at least one side wall of the plurality of sidewalls, both the first and second baffles disconnected from the crown,wherein the first baffle and the second baffle are in a staggeredconfiguration, the first baffle extending inwardly from at least oneside wall of the plurality of side walls to which it is coupled and thesecond baffle extending inwardly from at least one side wall of theplurality of side walls to which it is coupled to divide the meltingchamber into at least three melting sub-chambers that share the exhaustport, wherein at least one baffle of the plurality of baffles is afluid-cooled baffle configured to receive a cooling fluid from the atleast one side wall of the plurality of side walls to which it iscoupled; an inlet configured for introducing a glass batch to thesubmerged combustion melter; at least one outlet configured to removemolten glass from the at least three melting sub-chambers; and whereinthe at least three melting sub-chambers are configured to direct productflow in an undulating flow path between the inlet and the at least oneoutlet.
 2. The submerged combustion melter of claim 1, wherein at leastone of the bottom wall, at least one side wall of the plurality ofsidewalls, or the crown is fluid-cooled.
 3. The submerged combustionmelter of claim 1, wherein at least one of the bottom wall, at least oneside wall of the plurality of sidewalls, or the crown isnon-fluid-cooled.
 4. The submerged combustion melter of claim 1, whereinat least one baffle of the plurality of baffles is a non-fluid-cooledbaffle.
 5. The submerged combustion melter of claim 4, wherein thenon-fluid-cooled baffle includes a refractory material.
 6. The submergedcombustion melter of claim 5, wherein the refractory material includesat least one of silicon dioxide or aluminum oxide.
 7. The submergedcombustion melter of claim 1, wherein the cooling fluid includes atleast one of water, steam, or air.
 8. The submerged combustion melter ofclaim 1, wherein combustion gases from all the melting sub-chamberscollect in one exhaust chamber and exhaust from the exhaust port.
 9. Thesubmerged combustion melter of claim 1, wherein the plurality of bafflesfurther comprises a third baffle coupled to at least one side wall ofthe plurality of side walls, wherein the first baffle and the thirdbaffle are staggered from the second baffle.
 10. The submergedcombustion melter of claim 1, wherein molten glass flows in a verticallyundulated pattern between the inlet and the outlet.
 11. The submergedcombustion melter of claim 1, wherein at least one baffle of theplurality of baffles extends partially above a molten glass surface andmolten glass flows in a laterally undulated pattern between the inletand the at least one outlet.
 12. The submerged combustion melter ofclaim 11, wherein the first baffle is coupled to the third side wall andthe second baffle is coupled to the fourth side wall.
 13. The submergedcombustion melter of claim 1, wherein the plurality of baffles isdisconnected from the crown.
 14. The submerged combustion melter ofclaim 1, wherein at least one baffle of the plurality of baffles isremovable from at least one side wall of the plurality of the sidewalls.
 15. The submerged combustion melter of claim 1, wherein an angleof at least one baffle of the plurality of baffles is adjustable. 16.The submerged combustion melter of claim 1, wherein at least one baffleof the plurality of baffles is coupled to the bottom wall and at leastone side wall of the plurality of side walls.
 17. The submergedcombustion melter of claim 1, wherein the inlet is coupled to andextends through at least one side wall of the plurality of side walls orthe crown, wherein the inlet is disposed distal from the at least oneoutlet.
 18. The submerged combustion melter of claim 17, wherein the atleast one outlet is coupled to and extends through at least one sidewall of the plurality of side walls, wherein the at least one outlet isdisposed at least one of at a surface of the molten glass or below thesurface of the molten glass, and wherein the at least one outlet isdisposed distal from the inlet.
 19. The submerged combustion melter ofclaim 1, wherein the undulating flow path is generally along thelongitudinal axis that extends from the first side wall proximate to theinlet to the second side wall proximate to the at least one outlet andis along a vertically transverse axis that extends from the bottom wallto the crown.
 20. The submerged combustion melter of claim 1, whereinthe undulating flow path is generally along the longitudinal axis thatextends from the first side wall proximate to the inlet to the secondside wall proximate to the outlet and is along the laterally transverseaxis that extends from the third side wall to the fourth side wall. 21.The submerged combustion melter of claim 1, wherein the first baffle andthe second baffle are staggered along a vertically transverse axis. 22.The submerged combustion melter of claim 1, wherein both the firstbaffle and the second baffle are each coupled to two of the side wallsof the plurality of side walls, the two of the side walls being alongthe lateral transverse axis.
 23. The submerged combustion melter ofclaim 1, wherein the first baffle is coupled to the third side wall andthe second baffle is coupled to the fourth side wall.
 24. The submergedcombustion melter of claim 1, wherein the at least one outlet is belowthe molten glass surface.
 25. A submerged combustion melter system,comprising: a bottom wall; a plurality of side walls including a firstside wall, a second side wall, a third side wall, and a fourth side wallextending upwardly from the bottom wall; a longitudinal axis extendingfrom the first side wall to the second side wall; a laterally transverseaxis extending from the third side wall to the fourth side wall, thelaterally transverse axis perpendicular to the longitudinal axis; acrown extending inwardly with respect to the plurality of side walls andover the bottom wall to establish a melting chamber; an exhaust portconfigured to exhaust gas from the melting chamber; a plurality ofbaffles including a first baffle and a second baffle, the first bafflecoupled to at least one of the side walls of the plurality of side wallsand the second baffle coupled to at least one of the side walls of theplurality of side walls, both the first and second baffles disconnectedfrom the crown, wherein the first baffle and the second baffle are in astaggered configuration, the first baffle extending inwardly from atleast one of the side walls of the plurality of side walls to which itis coupled and the second baffle extending inwardly from at least one ofthe side walls of the plurality of side walls to which it is coupled todivide the melting chamber into at least three melting sub-chambers thatshare the exhaust port; an inlet configured for introducing a glassbatch to the submerged combustion melter; at least one outlet configuredto remove molten glass from the at least three melting sub-chambers; andat least one submerged combustion melting burner configured to providecombustible fuel to the melting chamber, wherein the at least threemelting sub-chambers are configured to direct product flow in anundulating flow path between the inlet and the at least one outlet, andwherein the undulating flow path is generally along the longitudinalaxis that extends from the first side wall proximate to the inlet to thesecond side wall proximate to the outlet and is along the laterallytransverse axis that extends from the third side wall to the fourth sidewall.
 26. The submerged combustion melter system of claim 25, wherein atleast one of the bottom wall, at least one of the side walls of theplurality of side walls, or the crown is fluid-cooled.
 27. The submergedcombustion melter system of claim 25, wherein at least one of the bottomwall, at least one of the side walls of the plurality of side walls, orthe crown is non-fluid-cooled.
 28. The submerged combustion meltersystem of claim 25, wherein at least one baffle of the plurality ofbaffles is a non-fluid-cooled baffle.
 29. The submerged combustionmelter system of claim 28, wherein the non-fluid-cooled baffle includesa refractory material.
 30. The submerged combustion melter system ofclaim 29, wherein the refractory material includes at least one ofsilicon dioxide or aluminum oxide.
 31. The submerged combustion meltersystem of claim 25, wherein at least one baffle of the plurality ofbaffles is a fluid-cooled baffle.
 32. The submerged combustion meltersystem of claim 31, wherein the at least one fluid-cooled baffle isconfigured to receive cooling fluid from at least one of the side wallsof the plurality of side walls.
 33. The submerged combustion meltersystem of claim 25, wherein the plurality of baffles further comprises athird baffle coupled to at least one of the side walls of the pluralityof side walls, wherein the first baffle and the third baffle arestaggered from the second baffle.
 34. The submerged combustion meltersystem of claim 25, wherein all the baffles of the plurality of bafflesare disconnected from the crown.
 35. The submerged combustion meltersystem of claim 25, wherein at least one baffle of the plurality ofbaffles is removable from at least one of the side walls of theplurality of side walls.
 36. The submerged combustion melter system ofclaim 25, wherein the inlet is coupled to and extends through at leastone of the side walls of the plurality of side walls or the crown,wherein the inlet is disposed distal from the at least one outlet. 37.The submerged combustion melter system of claim 25, wherein the at leastone submerged combustion melting burner is disposed proximate to atleast one of the bottom wall or at least one of the side walls of theplurality of side walls.
 38. The submerged combustion melter of claim25, wherein at least one baffle of the plurality of baffles extendspartially above a molten glass surface.
 39. A submerged combustionmelter, comprising: a bottom wall; a plurality of side walls including afirst side wall, a second side wall, a third side wall, and a fourthside wall extending upwardly from the bottom wall; a longitudinal axisextending from the first side wall to the second side wall; a laterallytransverse axis extending from the third side wall to the fourth sidewall, the laterally transverse axis perpendicular to the longitudinalaxis; a crown extending inwardly with respect to the plurality of sidewalls and over the bottom wall to establish a melting chamber; anexhaust port configured to exhaust gas from the melting chamber; aplurality of baffles including a first baffle and a second baffle, thefirst baffle coupled to at least one side wall of the plurality of sidewalls and the second baffle coupled to at least one side wall of theplurality of side walls, both the first and second baffles disconnectedfrom the crown, wherein the first baffle and the second baffle are in astaggered configuration, the first baffle extending inwardly from atleast one side wall of the plurality of side walls to which it iscoupled and the second baffle extending inwardly from at least one sidewall of the plurality of side walls to which it is coupled to divide themelting chamber into at least three melting sub-chambers that share theexhaust port; an inlet configured for introducing a glass batch to thesubmerged combustion melter; and at least one outlet configured toremove molten glass from the at least three melting sub-chambers;wherein at least one baffle of the plurality of baffles extendspartially above a molten glass surface and molten glass flows in alaterally undulated pattern between the inlet and the at least oneoutlet.
 40. The submerged combustion melter of claim 39, wherein atleast one of the bottom wall, at least one side wall of the plurality ofsidewalls, or the crown is fluid-cooled.
 41. The submerged combustionmelter of claim 39, wherein at least one of the bottom wall, at leastone side wall of the plurality of sidewalls, or the crown isnon-fluid-cooled.
 42. The submerged combustion melter of claim 39,wherein at least one baffle of the plurality of baffles is anon-fluid-cooled baffle.
 43. The submerged combustion melter of claim42, wherein the non-fluid-cooled baffle includes a refractory material.44. The submerged combustion melter of claim 43, wherein the refractorymaterial includes at least one of silicon dioxide or aluminum oxide. 45.The submerged combustion melter of claim 39, wherein at least one baffleof the plurality of baffles is a fluid-cooled baffle.
 46. The submergedcombustion melter of claim 45, wherein the fluid-cooled baffle isconfigured to receive cooling fluid from the at least one side wall ofthe plurality of side walls and wherein the cooling fluid includes atleast one of water, steam or air.
 47. The submerged combustion melter ofclaim 39, wherein combustion gases from all the melting sub-chamberscollect in one exhaust chamber and exhaust from one exhaust port. 48.The submerged combustion melter of claim 39, wherein the plurality ofbaffles further comprises a third baffle coupled to at least one sidewall of the plurality of side walls, wherein the first baffle and thethird baffle are staggered from the second baffle.
 49. The submergedcombustion melter of claim 39, wherein the plurality of baffles isdisconnected from the crown.
 50. The submerged combustion melter ofclaim 39, wherein at least one baffle of the plurality of baffles isremovable from at least one side wall of the plurality of the sidewalls.
 51. The submerged combustion melter of claim 39, wherein an angleof at least one baffle of the plurality of baffles is adjustable. 52.The submerged combustion melter of claim 39, wherein at least one baffleof the plurality of baffles is coupled to the bottom wall and at leastone side wall of the plurality of side walls.
 53. The submergedcombustion melter of claim 39, wherein the inlet is coupled to andextends through at least one side wall of the plurality of side walls orthe crown, wherein the inlet is disposed distal from the at least oneoutlet.
 54. The submerged combustion melter of claim 53, wherein the atleast one outlet is coupled to and extends through at least one sidewall of the plurality of side walls, wherein the at least one outlet isdisposed at least one of at a surface of the molten glass or below thesurface of the molten glass, and wherein the at least one outlet isdisposed distal from the inlet.
 55. The submerged combustion melter ofclaim 39, wherein the undulating flow path is generally along thelongitudinal axis that extends from the first side wall proximate to theinlet to the second side wall proximate to the outlet and is along thelaterally transverse axis that extends from the third side wall to thefourth side wall.
 56. A submerged combustion melter, comprising: abottom wall; a plurality of side walls including a first side wall, asecond side wall, a third side wall, and a fourth side wall extendingupwardly from the bottom wall; a longitudinal axis extending from thefirst side wall to the second side wall; a laterally transverse axisextending from the third side wall to the fourth side wall, thelaterally transverse axis perpendicular to the longitudinal axis; acrown extending inwardly with respect to the plurality of side walls andover the bottom wall to establish a melting chamber; an exhaust portconfigured to exhaust gas from the melting chamber; a plurality ofbaffles including a first baffle and a second baffle, the first bafflecoupled to at least one side wall of the plurality of side walls and thesecond baffle coupled to at least one side wall of the plurality of sidewalls, both the first and second baffles disconnected from the crown,wherein the first baffle and the second baffle are in a staggeredconfiguration, the first baffle extending inwardly from at least oneside wall of the plurality of side walls to which it is coupled and thesecond baffle extending inwardly from at least one side wall of theplurality of side walls to which it is coupled to divide the meltingchamber into at least three melting sub-chambers that share the exhaustport, and wherein an angle of at least one baffle of the plurality ofbaffles is adjustable; an inlet configured for introducing a glass batchto the submerged combustion melter; and at least one outlet configuredto remove molten glass from the at least three melting sub-chambers;wherein the at least three melting sub-chambers are configured to directproduct flow in an undulating flow path between the inlet and the atleast one outlet.